Method for the miniaturizable contacting of insulated wires

Abstract

The invention allows for the contacting of preferably microcomponents using electrical wires. By growing metallic microdepositions on cut surfaces of microcables, a contact region is generated which simplifies the dosing and application of a contact auxiliary and allows ultrasonic bonding, comprising a defined size of the electrically conductive area and allowing the contacting of very stably insulated wires. The application of this method in a panelized manner and in series is inexpensive.

The invention claimed is: 
     
       1. A method for contacting single insulated electrical wires, comprising
 forming a cross-sectional front surface on a single insulated electrical wire by cutting, the single insulated electrical wire having a wire of alloy components and an insulation, and 
 applying a ball-shaped or mushroom-shaped coating to the cross-sectional front surface by means of a coating process which takes place at temperatures below a melting temperature of the alloy components and below a temperature at which the insulation is destroyed, so that a defined contact region is formed by the coating on the wire and the wire comprises an enlarged diameter at the contact area due to the coating, whereas the coating extends over the insulated electrical wire and forms a flow stop edge at an angle a relative to the insulated electrical wire. 
 
     
     
       2. The method according to  claim 1 , wherein the cross-sectional front surface is exposed or formed by varying a cutting angle of a cutting tool or by crushing the wire to create an electrically conductive surface which is smaller than, equal to, or larger than the previous cross-sectional surface of the wire. 
     
     
       3. The method according to  claim 1 , wherein the coating of the cross-section front surface takes place electrochemically by galvanic coating, chemically reductive coating, immersion, or a combination of these methods. 
     
     
       4. The method according to  claim 1 , wherein the coating of the contact area comprises an increased surface roughness and an adapted surface activity. 
     
     
       5. The method according to  claim 1 , wherein the contacting of the wire with a component takes place by means of a contact auxiliary. 
     
     
       6. The method according to  claim 1 , wherein the contacting of the wire with a component takes place without contact auxiliary by means of welding methods. 
     
     
       7. The method according to  claim 1 , wherein one or more wires are processed simultaneously on a carrier. 
     
     
       8. The method according to  claim 1 , wherein one or more wires are processed simultaneously without a carrier. 
     
     
       9. The method according to  claim 1 , wherein the insulation is removed after processing and uninsulated wires with a very precisely defined contact region are able to be used. 
     
     
       10. The method according to  claim 4 , further comprising generating the increased surface roughness and the adapted surface activity of the coating of the contact area by self-enhancing tip growth due to electrostatic field magnification at tips, electrochemical roughening or a hydrophilic or hydrophobic additional coating in order to simplify a dosing of a contact auxiliary. 
     
     
       11. The method according to  claim 5 , wherein the contact auxiliary comprises solder or electrically conductive glue. 
     
     
       12. The method according to  claim 6 , wherein the welding methods include ultrasonic welding—bonding—or laser welding.